Rotary feeder with cleaning nozzles

ABSTRACT

A rotary feeder having a stationary, cylindrical housing having disposed therein a number of injection nozzles, and within which rotate a plurality of vanes about a central axis, wherein pairs of adjacent vanes of the plurality of vanes define wedge volumes, wherein the housing extends a width along the central axis, wherein each of the vanes has a length along the central axis, and wherein the injection nozzles are positioned across the width of the housing, such that a spray pattern of a gas injected via the number of injection nozzles spans substantially the entire length of the vanes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/985,854 filed May 22, 2018, published as U.S.Patent Application Publication No. US 2018/0353923 A1, which is anon-provisional of and claims priority to U.S. Provisional PatentApplication No. 62/516,230 filed Jun. 7, 2017 and both entitled “RotaryFeeder with Cleaning Nozzles,” each of which application is incorporatedby reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

TECHNICAL FIELD

The present disclosure relates to a rotary feeder comprising cleaningnozzles; more specifically, this disclosure relates to transferringpolymer within a polymerization system via a rotary feeder comprisingcleaning nozzles; still more specifically, the present disclosurerelates to utilizing a rotary feeder comprising cleaning nozzles totransfer polymer from an upstream unit to a downstream unit.

BACKGROUND

Rotary feeders can be utilized to transfer material from one unit orlocation to another within a process. For example, polymer products, orpolymer fluff, within a polymerization system may be transferred from apolymerization reactor to a downstream step, such as extrusion ofpolymer into pellets, via utilization of one or more rotary feeders.Prior to extrusion, equipment and processes may be utilized to purgesolvents or other fluids or contaminants that may be entrapped among thepolymer solids. Rotary feeders may be employed at one or more locationsto transfer polymer from upstream equipment to downstream equipment suchas conveying systems involving hydraulics, pneumatics, pressurized air,or a combination thereof; high pressure and low pressure solvent flashand recovery systems; flow control systems; lock hoppers; purge vessels;degassers; disengaging vessels; and the like.

With existing designs, polymer fluff, which may be sticky, can build upon internals of transfer apparatus, such as on the vanes of rotaryfeeders. When a desired production rate cannot be maintained due to thebuildup (e.g., when an increase in rotation speed of a rotary feedercannot provide adequate polymer fluff transfer due to decreasedavailable fill volume as a result of polymer buildup on the vanesthereof), undesirable downtime may be needed for cleaning of thetransfer apparatus. The cost of such downtime, and the equipment andpower necessary to effect movement of the polymer between thepolymerization reactor(s) and a downstream unit may be substantial.Accordingly, a need exists for more efficient polymer transferapparatus, systems and methods.

BRIEF SUMMARY

Disclosed herein is a rotary feeder comprising: a stationary,cylindrical housing having disposed therein a number of injectionnozzles, and within which rotate a plurality of vanes about a centralaxis, wherein pairs of adjacent vanes of the plurality of vanes definewedge volumes, wherein the housing extends a width along the centralaxis, wherein each of the vanes has a length along the central axis, andwherein the injection nozzles are positioned across the width of thehousing, such that a spray pattern of a gas injected via the number ofinjection nozzles spans substantially the entire length of the vanes.

Further disclosed herein is a rotary feeder comprising: a stationary,cylindrical housing having disposed therein a number of injectionnozzles, and within which rotate a plurality of vanes about a centralaxis, wherein the housing extends a width along the central axis,wherein each of the vanes has a length along the central axis, whereinthe injection nozzles are positioned across the width of the housing,such that a spray pattern of a gas injected via the number of injectionnozzles spans substantially the entire length of the vanes, and whereineach of the number of injection nozzles is located at a position along acircumference of the housing that is in the range of from about 50° toabout 170° from an inlet of the rotary feeder, along a direction ofrotation of the plurality of vanes.

Also disclosed herein is a rotary feeder comprising: a stationary,cylindrical housing having disposed therein a number of injectionnozzles, and within which rotate a plurality of vanes about a centralaxis, wherein the housing extends a width along the central axis fromend walls thereof, wherein each of the vanes extends a length along thecentral axis, wherein the length each of the plurality of vanes extendsalong the central axis is slightly less than the width of the housingalong the central axis, such that the each of the plurality of vanesextends almost to the end walls of the housing and can rotate freelywithin the housing, and wherein the injection nozzles are positionedacross the width of the housing, such that a spray pattern of a gasinjected via the number of injection nozzles spans substantially theentire length of the vanes.

Further disclosed herein is a rotary feeder comprising: a stationary,cylindrical housing having disposed therein a number of injectionnozzles, and within which rotate a plurality of vanes about a centralaxis, wherein the stationary, cylindrical housing defines an inlet andan outlet, wherein the inlet is positioned at a top of the housing, andthe outlet is positioned at a bottom of the housing, wherein the housingextends a width along the central axis, wherein each of the vanes has alength along the central axis, and wherein the injection nozzles arepositioned across the width of the housing, such that a spray pattern ofa gas injected via the number of injection nozzles spans substantiallythe entire length of the vanes.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will reference the drawings briefly describedbelow, wherein like reference numerals represent like parts, unlessotherwise indicated. The inventive concepts disclosed and claimed hereinmay be better understood by reference to one or more of these figures incombination with the detailed description of specific embodimentspresented herein.

FIG. 1A illustrates a cross-section view of a rotary feeder according toan embodiment of this disclosure;

FIG. 1B illustrates a view of the rotary feeder of FIG. 1A taken alongvertical axis B-B;

FIG. 2 illustrates a schematic of a polymerization system 100 accordingto an embodiment of this disclosure;

FIG. 3 illustrates a schematic of a polymerization system 100A accordingto another embodiment of this disclosure;

FIG. 4 illustrates a schematic of a polymerization system 100B accordingto another embodiment of this disclosure; and

FIG. 5 illustrates a schematic of a polymerization system 100C accordingto another embodiment of this disclosure.

While the inventive concepts disclosed herein are susceptible to variousmodifications and alternative forms, only a few specific embodimentshave been shown by way of example in the drawings and are described indetail below. The figures and detailed descriptions of these specificembodiments are not intended to limit the breadth or scope of theinventive concepts or the appended claims in any manner. Rather, thefigures and detailed written descriptions are provided to illustrate theinventive concepts to a person of ordinary skill in the art and toenable such person to make and use the inventive concepts.

DETAILED DESCRIPTION

Disclosed herein is a rotary feeder (also referred to herein as a‘rotary valve’) comprising cleaning apparatus configured to spray vanesof the rotary feeder with a gas whereby buildup of material on the vanesmay be reduced relative to a rotary feeder not comprising such cleaningapparatus. Such buildup undesirably takes up volume within a rotaryfeeder, reducing the amount of material that can be transported by therotary feeder. In embodiments, the cleaning apparatus of theherein-disclosed rotary feeder may comprise tubing or other conduit forthe introduction of gas into the rotary feeder; however, incorporationof injection nozzles, as described hereinbelow, which may provide aparticular spray pattern, may more effectively clean the interiorsurfaces (e.g., the rotating vanes) of the rotary feeder, and thefollowing description will be made with reference to such injectionnozzles. A rotary feeder as described herein may be particularlysuitable for use in transferring a sticky material, such as a polymer(also referred to herein as a polymer ‘fluff’ or ‘flake’) produced in apolymerization reactor, which may be located upstream of theherein-disclosed rotary feeder in polymer transfer systems comprisingthe rotary feeder.

FIG. 1A illustrates a cross-section view of a rotary feeder 10 accordingto an embodiment of this disclosure. FIG. 1B illustrates a view ofrotary feeder 10 of FIG. 1A taken along vertical axis B-B. These will bediscussed in combination. Rotary feeder 10 comprises a stationary,cylindrical housing 20 having disposed therein a number of injectionnozzles 36, and within which rotate a plurality of vanes 30 about acentral axis 35. Housing 20 extends a width W along central axis 35, andeach of the vanes 30 has a length L along the central axis 35. Injectionnozzles 36 are positioned across the width W of housing 20, such that aspray pattern SP of a gas injected via the number of injection nozzles36 spans substantially the entire length L of the vanes 30, wherebyinjected gas can spray the vanes 30, cleaning them as they rotate pastthe injection nozzles 36. Cylindrical housing 20 may have an outerdiameter 21 and inner diameter 22.

A rotary feeder of any desired size can be configured with injectionnozzles according to this disclosure. In embodiments, the length L ofeach vane 30 is in the range of from about 10 inches (25.4 cm) to about50 inches (127 cm), from about 10 inches (25.4 cm) to about 30 inches(76.2 cm), or from about 12 inches (30.5 cm) to about 20 inches (50.8cm). In embodiments, the length L of each vane 30 is approximately equalto 12, 13, 14, 15, 16, 17, 18, 19, or 20 inches (30.5, 33.0, 35.6, 38.1,40.6, 43.2, 45.7, 48.3, or 50.8 cm). In embodiments, length L of eachvane 30 is slightly less (e.g., less than 1, 0.5, 0.25, 0.15, 0.1 or0.05 inch (25.4, 12.7, 6.35, 3.81, 2.54, or 1.27 mm)) than width W ofhousing 20 such that vanes 30 are positioned adjacent to the housing endwall and can rotate freely therewithin during operation of rotary feeder10.

Stationary, cylindrical housing 20 may further define an inlet and anoutlet. The inlet may be positioned proximate a top T of the housing,and the outlet may be positioned proximate a bottom B of the housing.For example, as indicated in the embodiment of FIGS. 1A and 1B,cylindrical housing 20 of rotary feeder 10 defines inlet 15 and outlet25, with inlet 15 located at a top of rotary feeder 10, and outlet 25located at a bottom thereof. In an embodiment, the inlet and outlet arelocated about 190°, 185°, 180°, 175° or 170° opposite of each other.

As illustrated in FIG. 1A, injection nozzles 36 can be positioned at anylocation along housing 20. In embodiments, the injection nozzles 36 arepositioned such that wedge volumes WV defined by two adjacent vanes 30of the rotary feeder are substantially full when they rotate past thelocation of injection nozzles 36 within housing 20. In embodiments, eachof the number of injection nozzles 36 may be located at a position alonga circumference of housing 20 that is an angle α in the range of fromabout 50° to about 170°, from about 70° to about 160°, or from about 90°to about 160° from a top or inlet 15 of rotary feeder 10, alongdirection of rotation R of the plurality of vanes 30. In embodiments,angle α is about equal to 150°, 155°, 160°, 165°, or 170°. Suchpositioning may be desirable such that the presence of sprayed gaswithin the wedge volumes WV does not limit the introduction ofadditional material (e.g., polymer flake) into rotary feeder 10 viainlet 15 thereof. However, in alternative embodiments, the injectionnozzles 36 are positioned so that wedge volumes WV defined by the vanes30 of rotary feeder 10 are substantially empty when they rotate past theinjection nozzles. In such embodiments, each of the number of injectionnozzles 36 may be located at a position along a circumference of housing20 that is an angle α in the range of from about 200° to less than 360°,from about 200° to about 270°, or from about 200° to about 300° from atop or inlet 15 of rotary feeder 10, along direction of rotation R ofthe plurality of vanes 30. Although R is indicated as clockwise rotationin the embodiment of FIG. 1A, counterclockwise rotation is alsoenvisioned, in embodiments. Vanes 30 may have a leading side facing thedirection of rotation R, and a trailing side obverse, and the injectionnozzles 36 may be oriented to spray gas onto the leading side, thetrailing side, or both.

In embodiments, injection nozzles 36 are located substantially in astraight line (e.g., co-planer or sharing a common central axis) acrossthe width W of housing 20. In embodiments, the injection nozzles 36 arelocated along a horizontal line such that each injection nozzle isapproximately the same angle α from a top or inlet 15 of rotary feeder10, and thereby share a common central axis passing through the housingwall along the width, W. In embodiments, the line of injection nozzles36 is located at a position along the circumference of housing 20 thatis an angle α in the range of from about 90 degrees to about 160 degreesfrom the inlet, along the direction of rotation R of the plurality ofvanes 30. In embodiments, not shown in FIG. 1B, the injection nozzlesspan the width W of housing 20 along a line at an angle from axis ofrotation 35, such that each nozzle is at a different angle α from inlet15.

In embodiments, injection nozzles 36 are positioned substantiallyequidistantly apart across the width W of housing 20. A center-to-centerdistance D between adjacent injection nozzles 36 may be equal to thewidth W of housing 20 divided by the number of injection nozzles 36. Inembodiments, the center-to-center distance D may be in the range of fromabout 1 inch (2.54 cm) to about 10 inches (25.4 cm), from about 2 inches(5.1 cm) to about 7 inches (17.8 cm), from about 2 inches (5.1 cm) toabout 4 inches 10.2 cm), or equal to about 2, 3, 4, 5, 6, 7, 8, 9, or 10inches (5.1, 7.6, 10.2, 12.7, 15.2, 17.8, 20.3, 22.9, or 25.4 cm).

In embodiments, a first injection nozzle and a last injection nozzleacross the width W of the housing 20 are located a distance D′ along thecentral axis 35, from an end of the housing closest thereto, that isabout equal to half the center-to-center distance D between adjacentinjection nozzles 36 (or, stated differently, distance D′ is the width Wof the housing divided by two times the number of injection nozzles).Thus, in embodiments, D′ equals half of D. For example, in theembodiment of FIG. 1B, first injection nozzle 1 is located a distance D′along central axis 35 from first end 22A of housing 20 and lastinjection nozzle 4 is located a distance D′ along central axis 35 fromsecond end 22B of housing 20 that is about equal to the width W of thehousing 20 divided by two times the number of injection nozzles.

The number of injection nozzles may be determined by dividing the widthW of housing 20 by a desired spacing D between injection nozzles 36. Inembodiments, the rotary feeder has disposed therein from 2 to 10, from 3to 9, or from 4 to 5 injection nozzles. Rotary feeder 10 of FIG. 1Bcomprises injection nozzles 1, 2, 3, and 4.

Each of the number of injection nozzles 36 may be configured to providea desired spray pattern. In embodiments, such desired spray pattern maybe selected from fan patterns, air-knife patterns, or combinationsthereof. For example, the spray pattern SP depicted in the embodiment ofFIG. 1B is a fan spray pattern. Any suitable nozzle known in the art maybe utilized. In embodiments, the injection nozzles are hydroblastnozzles. In embodiments, the nozzles are Standard Fan Nozzles availablefrom BETE Fog Nozzle, Inc. in Greenfield, MA In embodiments, the nozzlesare ¼ inch BETE standard fan nozzles, such as, for example, number NF70,having a 120° spray angle. In embodiments, the nozzles are nozzles asdescribed in U.S. patent application Ser. No. 10/808,245, which isincorporated by reference herein in its entirety. Each of the injectionnozzles 36 may be a one-piece construction. The injection nozzles 36 canbe made of any suitable material. For example, in embodiments, injectionnozzles 36 are constructed of brass, 303 stainless steel, 316 stainlesssteel, polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), or acombination thereof.

Injection nozzles 36 may provide a spray pattern SP with a spray angle βin the range of from about 15° to about 120°, from about 90° to about120°, from about 100° to about 120°, from about 110° to about 120°, orequal to about 90°, 100°, 110°, or 120°. The injection nozzles 36 may bepositioned across width W of housing 20 such that the spray pattern SPof each of the number of injection nozzles 36 overlaps the spray patternof at least one adjacent nozzle 36. For example, the SP of an injectionnozzle may extend a lengthy along vane 30 (i.e., at the distance of vane30), and may overlap a distance x of the spray pattern provided by anadjacent nozzle. The spray pattern SP of each of the number of injectionnozzles 36 may overlap the spray pattern of at least one adjacent nozzleby a percentage (x/y) in the range of from about 10% to about 50%, fromabout 10% to about 40%, or from about 10% to about 30%, or equal to atleast 10%, 20%, or 30%.

Each of the spray nozzles 36 may be fluidly connected with a gas source71 via one or more gas feed lines 70 (not shown to scale in FIG. 1A). Inan embodiment, each of the spray nozzles 36 may be fluidly connected viaa common gas distribution header in fluid communication with each nozzleand the gas source 71. Gas feed line 70 may have an inside diameter inthe range of from about ¼ inch (6.35 mm) to about ⅜ inch (9.525 mm),from about 5/16 inch (7.9375 mm) to about ½ inch (12.7 mm), or fromabout ¼ inch (6.35 mm) to about ½ inch (12.7 mm), or equal to about ½inch (12.7 mm), ¼ inch (6.35 mm), or % inch (9.525 mm). Gas source 71may provide gas at a pressure in the range of from about 30 psi (0.21MPa) to about 70 psi (0.48 MPa), from about 40 psi (0.28 MPa) to about60 psi (0.41 MPa), or from about 50 psi (0.34 MPa) to about 60 psi (0.41MPa), or equal to about 30 psi (0.21 MPa), 40 psi (0.28 MPa), 50 psi(0.34 MPa), 60 psi (0.41 MPa), or 70 psi (0.48 MPa).

Also disclosed herein is a system comprising a rotary feeder of thisdisclosure, for example a polymerization system comprising a polymertransport subsystem for transferring polymer from an upstreampolymerization reactor to downstream equipment such as a pelletizationextruder. Such a system can comprise a rotary feeder comprisinginjection nozzles as per this disclosure and configured to transfer amaterial (such as a polymer product) from equipment (e.g., a vessel)upstream of the rotary feeder, to equipment (e.g., a vessel) downstreamof the rotary feeder that is configured to receive the material from therotary feeder. Such a system can comprise one or more polymerizationreactors configured to produce a product polymer, and a rotary feedercomprising injection nozzles as per this disclosure and configured totransfer the polymer product from equipment (e.g., a vessel) upstream ofthe rotary feeder that is configured to receive the polymer productproduced in the one or more polymerization reactors, to equipment (e.g.,a vessel) downstream of the rotary feeder that is configured to receivepolymer product from the rotary feeder. Examples of equipment present ina polymer transport process include conveying systems involvinghydraulics, pneumatics, pressurized air, or a combination thereof; highpressure and low pressure solvent flash and recovery systems; flowcontrol systems; lock hoppers; purge vessels; degassers; disengagingvessels; storage or feed vessels, and the like. Although not shown inthe Figures, the herein-disclosed system may additionally comprise anyequipment associated with a polymerization process, such as pumps,control devices (e.g., a PID controller), measurement instruments (e.g.,thermocouples, transducers, and flow meters), alternative inlet andoutlet lines, etc., as known in the art.

Description of a system of this disclosure will now be made withreference to FIG. 2 , which is a schematic illustration of apolymerization system 100 according to an embodiment of this disclosure.As noted above, a system of this disclosure can comprise an upstreamvessel UV from which material is transferred to a rotary feeder 10′ ofthis disclosure, and then to a downstream vessel DV to which the rotaryfeeder of this disclosure transfers the material, and may furthercomprise a vessel or reactor (which may be upstream of upstream vesselUV) configured to produce the material to be transferred via the rotaryfeeder. For example, as noted above, a system of this disclosure maycomprise at least one polymerization reactor 40 operable to produce aproduct polymer. System 100 of the embodiment of FIG. 2 comprisespolymerization reactor 40, upstream vessel UV, rotary feeder 10′, anddownstream vessel DV. Each of the components of system 100 will bedescribed in further detail hereinbelow.

As used herein, the terms “polymerization reactor” or “reactor” mayinclude at least one reactor in which polymerization of olefin monomersor comonomers to produce homopolymers or copolymers can be effected.Such homopolymers and copolymers may be referred to herein as polymers,polymer product, resins, polymer fluff, or polymer flake.

Polymerization reactor 40 is operable to produce a product polymer, orpolymer ‘fluff’, from a feed introduced thereto via polymerization feedline(s) 41, and in the presence of a catalyst, which can be introducedvia catalyst feeder 42 and catalyst feed line 43. Polymer flufftypically refers to virgin or untreated polymer produced in the reactorand prior to the addition of any additives (e.g., stabilizers) and/orundergoing any further processing (e.g., prior to pelletization).Polymerization reactor 40 may comprise any vessel or combination ofvessels suitably configured to provide an environment for a chemicalreaction (e.g., a contact zone) between monomers (e.g., ethylene) and/orpolymers (e.g., an “active” or growing polymer chain), and optionallycomonomers (e.g., butene-1, hexene) and/or copolymers, in the presenceof a catalyst to yield a polymer (e.g., a polyethylene polymer) and/orcopolymer. Although the embodiment illustrated in FIG. 2 shows a singlepolymerization reactor 40, one of skill in the art viewing thisdisclosure will recognize that any suitable number and/or configurationof polymerization reactors may be employed.

In various embodiments, polymerization reactor 40 may be a gas phasefluidized bed reactor, a loop slurry reactor, a stirred tank reactor, anaxial flow reactor, a horizontal gas phase reactor, or a combinationthereof. In embodiments, a system of this disclosure comprises at leastone gas phase or slurry loop polymerization reactor. In embodiments, thesystem provided herein comprises more than one polymerization reactor.In embodiments, the polymerization system comprises more than onereactor in series. In embodiments, the more than one polymerizationreactor in series is operated to pass polymer continuously from onepolymerization reactor to another.

The polymerization processes performed in the reactor(s) (e.g., reactor40) may include batch or continuous processes. Continuous processes mayemploy intermittent or continuous product discharge. Processes may alsoinclude partial or full direct recycle of unreacted monomer, unreactedcomonomer, diluent, or a combination thereof. In embodiments, polymer iscontinuously withdrawn from polymerization reactor 40 via polymerproduct line 45. In embodiments, polymer is continuously withdrawn froma gas phase fluidized bed polymerization reactor 40. In embodiments,polymer is continuously withdrawn from a loop slurry polymerizationreactor 40.

In embodiments comprising multiple reactors, production ofpolymerization product in multiple reactors may include several stagesprovided by at least two separate polymerization reactors interconnectedby a transfer device making it possible to transfer the polymerizationproduct resulting from a first polymerization reactor into a secondpolymerization reactor. The desired polymerization conditions in onepolymerization reactor may be different from the polymerizationconditions of the other polymerization reactor(s). Alternatively,polymerization in multiple reactors may include the manual transfer ofpolymerization product (e.g., in a polymerization product slurry, as amixture, as solid polymer, or combinations thereof) from onepolymerization reactor to subsequent polymerization reactor(s) forcontinued polymerization. Multiple reactor systems may comprise anycombination including, without limitation, multiple loop reactors, acombination of loop and gas reactors, multiple high-pressure reactors,or a combination of high pressure with one or more of loop and gasreactors. The multiple polymerization reactors may be operated inseries, in parallel, or combinations thereof.

Operating conditions for the polymerization in polymerization reactor 40may vary depending on polymerization reactor type. For example, thepolymerization reactor may be operated at pressures of from about 100psig (0.69 MPa) to about 75,000 psig (517.11 MPa). In embodiments, thepolymerization reactor may be a loop slurry reactor operated atpressures of from about 550 psig (3.79 MPa) to about 800 psig (5.52MPa); alternatively, a gas phase reactor operated at pressures of fromabout 100 psig (0.69 MPa) to about 500 psig (3.45 MPa); alternatively, ahorizontal gas phase reactor operated at pressures of from about 250psig (1.72 MPa) to about 350 psig (2.41 MPa); alternatively, an axialflow reactor operated at pressures of from about 100 psig (0.69 MPa) toabout 5000 psig (34.47 MPa; alternatively, an autoclave reactor operatedat pressures of from about 15,000 psig (103.42 MPa) to about 32,500 psig(224.08 MPa); alternatively, a tubular reactor operated at pressures offrom about 30,000 psig (206.84 MPa) to about 60,000 psig (413.69 MPa).

Monomer, diluent, catalyst, any comonomer, various additives, or acombination thereof, which may be fed to the polymerization reactor 40(e.g., via one or more polymerization feed line(s) 41), may circulatethrough the reactor as polymerization occurs. Generally, continuousprocesses may comprise the continuous introduction of a monomer, anoptional comonomer, a catalyst, a diluent, etc., into polymerizationreactor 40, and the continuous removal (e.g., via polymer product line45) of a polymer product (which may be, for example, a slurry or gaseousphase) comprising solid polymer (e.g., polyethylene).

In embodiments, the monomer comprises an α-olefin, such as, withoutlimitation, ethylene (ethene) or propylene (propene). In embodiments, acomonomer comprises an unsaturated hydrocarbon having from 3 to 12carbon atoms. For example, a comonomer may comprise propene, butene-1,hexene-1, octenes, or combinations thereof.

In embodiments having multiple polymerization reactors, various types ofreactors that may additionally be included in system 100 may compriseloop slurry polymerization reactors. Such reactors may have a loopconfiguration, as known in the art. In embodiments, suitable diluentsused in a slurry polymerization process may include, but are not limitedto, the monomer, and optionally, the comonomer, being polymerized andhydrocarbons that are liquids under reaction conditions. Examples ofsuitable diluents include, but are not limited to, hydrocarbons such aspropane, cyclohexane, isobutane, n-butane, n-pentane, isopentane,neopentane, and n-hexane. In embodiments, diluents may compriseunsaturated hydrocarbons having from 3 to 12 carbon atoms. Furtherexamples of suitable diluents include, but are not limited to propene,butene-1, hexene-1, octenes, or combinations thereof. Some looppolymerization reactions can occur under bulk conditions where nodiluent is used. An example is polymerization of propylene monomer asdisclosed in U.S. Pat. No. 5,455,314, which is hereby incorporated byreference herein in its entirety for all purposes not contrary to thisdisclosure.

A typical loop polymerization process is disclosed, for example, in U.S.Pat. Nos. 3,248,179, 4,501,885, 5,565,175, 5,575,979, 6,239,235,6,262,191, 6,833,415, and 8,921,498, the disclosure of each of which isincorporated herein by reference in its entirety for all purposes notcontrary to this disclosure.

In embodiments having multiple polymerization reactors, various types ofreactors that may additionally be included in system 100 may comprisegas-phase reactors. Gas-phase reactors may comprise fluidized bedreactors or staged horizontal reactors. Gas-phase reactors may employ acontinuous recycle stream containing one or more monomers continuouslycycled through a fluidized bed in the presence of the catalyst underpolymerization conditions. A recycle stream may be withdrawn from thefluidized bed and recycled back into the polymerization reactor.Simultaneously, polymer product may be withdrawn from the polymerizationreactor and new or fresh monomer may be added to replace the polymerizedmonomer. Likewise, copolymer product may optionally be withdrawn fromthe reactor and new or fresh comonomer may be added to replacepolymerized comonomer, polymerized monomer, or combinations thereof.Such gas phase polymerization reactors may comprise a process formulti-step gas-phase polymerization of olefins, in which olefins arepolymerized in the gaseous phase in at least two independent gas-phasepolymerization zones while feeding a catalyst-containing polymer formedin a first polymerization zone to a second polymerization zone. Such gasphase reactor may be as disclosed in U.S. Pat. Nos. 5,352,749, 4,588,790or 5,436,304, each of which is hereby incorporated herein by referencein its entirety for all purposes not contrary to this disclosure.

In embodiments having multiple polymerization reactors, various types ofreactors that may additionally be included in system 100 may comprisehigh-pressure reactors. High-pressure reactors may comprise autoclave ortubular reactors. Tubular reactors may have several zones where freshmonomer (optionally, comonomer), initiators, or catalysts may be added.Monomer (optionally, comonomer) may be entrained in an inert gaseousstream and introduced at one zone of the polymerization reactor.Initiators, catalysts, catalyst components, or a combination thereof maybe entrained in a gaseous stream and introduced at another zone of thereactor. The gas streams may be intermixed for polymerization. Heat andpressure may be employed appropriately to obtain optimal polymerizationreaction conditions.

In embodiments having multiple reactors, various types of reactors thatmay additionally be included in system 100 may comprise a solutionpolymerization reactor wherein the monomer (optionally, comonomer) maybe contacted with the catalyst composition by suitable stirring or othermeans. A carrier comprising an inert organic diluent or excess monomer(optionally, comonomer) may be employed. If desired, the monomer,optional comonomer, or both may be brought in the vapor phase intocontact with the catalytic reaction product, in the presence or absenceof liquid material. The polymerization zone may be maintained attemperatures and pressures that will result in the formation of asolution of the polymer in a reaction medium. Agitation may be employedto obtain better temperature control and to maintain uniformpolymerization mixtures throughout the polymerization zone. Adequatemeans can be utilized for dissipating the exothermic heat ofpolymerization.

Conditions of a polymerization reactor, e.g., polymerization reactor 40,which may be chosen and even controlled for polymerization efficiencyand to provide resin properties include temperature, pressure and theconcentrations of various reactants. Polymerization temperature canaffect catalyst productivity, polymer molecular weight and molecularweight distribution. Suitable polymerization temperature may be anytemperature below the de-polymerization temperature according to theGibbs free energy equation. Typically, this includes from about 60° C.(140° F.) to about 280° C. (536° F.), for example, or from about 70° C.(158° F.) to about 110° C. (230° F.), depending upon the type ofpolymerization reactor.

As noted hereinabove, suitable pressures will also vary according to thereactor and polymerization type. The pressure for liquid phasepolymerizations in a loop reactor such as loop slurry polymerizationreactor is typically less than 1,000 psig (6.9 MPa), for example, about650 psig (4.5 MPa). Pressure for gas phase polymerization is usuallyfrom about 200 psig (1.4 MPa) to about 500 psig (3.4 MPa). High-pressurepolymerization in tubular or autoclave reactors is generally run atabout 20,000 psig (137.9 MPa) to 60,000 psig (413.7 MPa). Polymerizationreactors can also be operated in a supercritical region occurring atgenerally higher temperatures and pressures. Operation above thecritical point of a pressure/temperature diagram (supercritical phase)may offer advantages. In an embodiment, polymerization may occur in anenvironment having a suitable combination of temperature and pressure.For example, polymerization may occur at a pressure in a range of about400 psi (2.8 MPa) to about 1,000 psi (6.9 MPa); alternatively, about 550psi (3.8 MPa) to about 650 psi (4.5 MPa), alternatively, about 600 psi(4.1 MPa) to about 625 psi (4.3 MPa); and a temperature in a range ofabout 66° C. (150° F.) to about 110° C. (230° F.), alternatively, fromabout 91° C. (195° F.) to about 104° C. (220° F.).

The concentration of various reactants can be controlled to producesolid polymer with certain physical and mechanical properties. Theproposed end-use product that will be formed by the solid polymer andthe method of forming that product determines the desired properties.Mechanical properties include tensile, flexural, impact, creep, stressrelaxation and hardness tests. Physical properties include density,molecular weight, molecular weight distribution, melting temperature,glass transition temperature, temperature melt of crystallization,density, stereoregularity, crack growth, long chain branching andrheological measurements.

The concentrations, partial pressures, or both of the monomer,comonomer, hydrogen, co-catalyst, modifiers, and electron donors areimportant in producing these resin properties. Comonomer may be used tocontrol product density. Hydrogen may be used to control productmolecular weight. Co-catalysts can be used to alkylate, scavenge poisonsand control molecular weight. Activator-support can be used to activateand support the catalyst. Modifiers can be used to control productproperties and electron donors affect stereoregularity, the molecularweight distribution, or molecular weight. In addition, the concentrationof poisons may be minimized because poisons impact the reactions andproduct properties.

Thus, polymerization reaction components of the polymerizationreactor(s) disclosed herein (e.g., polymerization reactor 40) mayinclude olefin monomers (e.g., ethylene) and comonomers (e.g., hexene),diluent (e.g., isobutane, hexane, propane, or combinations thereof),molecular weight control agents (e.g., hydrogen), and any other desiredco-reactants or additives. Polymerization reaction components mayadditionally include a catalyst, and optionally, a co-catalyst. Suitablecatalyst for polymerizing the monomers and any comonomers may include,but is not limited to a catalyst(s) and, optionally, a co-catalyst(s), apromoter(s), or a combination thereof. Non-limiting examples of suitablecatalyst systems include Ziegler Natta catalysts, Ziegler catalysts,chromium catalysts, chromium oxide catalysts, chromocene catalysts,metallocene catalysts, nickel catalysts, and combinations thereof.Non-limiting examples of co-catalyst include triethylboron, methylaluminoxane, alkyls such as triethylaluminum, and combinations thereof.Suitable activator-supports may comprise solid super acid compounds.Without limitation, catalyst systems suitable for use in thepolymerization reactor(s) of this disclosure have been described, forexample, in U.S. Pat. No. 7,619,047 and U.S. Patent ApplicationPublications No. 2007/0197374, 2009/0004417, 2010/0029872, 2006/0094590,and 2010/0041842, the disclosure of each of which is hereby incorporatedherein by reference in its entirety for all purposes not contrary tothis disclosure.

In an embodiment, the polymerization reactor product in line 45 (45A inthe embodiments of FIGS. 3 and 5 , which are described furtherhereinbelow) comprises polyolefins, which may be homopolymers orcopolymers. In embodiments, the polymerization reactor product comprisespolyethylene, polypropylene, polybutadiene, polybutene,polymethylpentene, or a combination thereof. In embodiments, the reactorproduct comprises copolymers of ethylene with propylene, butene, hexene,octene, or a combination thereof. The weight percent solids of thepolymer product may vary. In an embodiment, the polymerization reactoris a liquid phase reactor (e.g., a loop slurry reactor) and comprisesfrom about 0 to about 66 weight percent polyethylene solids.

In embodiments, the polymerization product comprises solid polymer and aliquid phase of a diluent. In an embodiment, the polymerization productcomprises unreacted monomer, unreacted comonomer, or both in a liquidphase. In additional or alternative embodiments, the polymerizationproduct may generally comprise various solids, semi-solids, volatile andnonvolatile liquids, or combinations thereof. In an embodiment, thepolymerization product comprises one or more of hydrogen, nitrogen,methane, ethylene, ethane, propylene, propane, butane, isobutane,pentane, hexane, hexene-1 and heavier hydrocarbons. In an embodiment,ethylene may be present in a range of from about 0.1% to about 15%,alternatively, from about 1.5% to about 5%, alternatively, about 2% toabout 4% by total weight of the liquid in polymerization product line45/45A. Ethane may be present in a range of from about 0.001% to about4%, alternatively, from about 0.2% to about 0.5% by total weight of thematerial in the polymerization product line 45/45A. Isobutane may bepresent in a range from about 80% to about 98%, alternatively, fromabout 92% to about 96%, alternatively, about 95% by total weight of thematerial in the polymerization product line 45/45A.

In embodiments, the polymerization product comprises a mixture of thesolid polymer and a vapor phase of at least a portion of the diluent. Inadditional or alternative embodiments, the mixture may compriseunreacted, gaseous monomers or optional comonomers (e.g., unreactedethylene monomers, unreacted butene-1 monomers), gaseous waste products,gaseous contaminants, or combinations thereof. As used herein, an“unreacted monomer,” for example, ethylene, refers to a monomer that wasintroduced into a polymerization reactor during a polymerizationreaction but was not incorporated into a polymer. As used herein, an“unreacted comonomer,” for example, butene-1, refers to a comonomer thatwas introduced into a polymerization reactor during a polymerizationreaction but was not incorporated into a polymer. Such gaseous phaseproduct mixtures may be present when gas phase polymerization reactor(s)are utilized in rather than or in addition to a loop slurry reactor(s).

In embodiments, the solid polymer may comprise a homopolymer, acopolymer, or combinations thereof. The homopolymer, the polymers of thecopolymer, or both may comprise a multimodal (e.g., a bimodal) polymer(e.g., polyethylene). For example, the solid polymer may comprise both arelatively high molecular weight, low density (HMWLD) polyethylenepolymer component and a relatively low molecular weight, high density(LMWHD) polyethylene polymer component. Various types of suitablepolymers may be characterized as having a various densities. Forexample, a Type I may be characterized as having a density in a range offrom about 0.910 g/cm³ to about 0.925 g/cm³, alternatively, a Type IImay be characterized as having a density from about 0.926 g/cm³ to about0.940 g/cm³, alternatively, a Type III may be characterized as having adensity from about 0.941 g/cm³ to about 0.959 g/cm³, alternatively, aType IV may be characterized as having a density of greater than about0.960 g/cm³. The solid polymer may comprise other polyolefin polymers.In embodiments, the polymer product produced in polymerizationreactor(s) 40 is a low density polymer, a Type I polymer, a Type IIpolymer, a Type III polymer, a Type IV polymer, or a combinationthereof.

With continued reference to FIG. 2 , a rotary feeder 10′ is operable totransfer material, such as, without limitation, polymerization productcomprising polymer fluff, from a vessel upstream of the rotary feeder.Rotary feeder 10′ may be a rotary feeder comprising cleaning nozzles asdescribed herein above with reference to FIG. 1 . Although indicated inthe embodiment of FIG. 2 as being in direct connection withpolymerization reactor 40, via polymer product line 45, the upstreamvessel or ‘UV’ can be any vessel downstream of polymerization reactor 40into which polymer fluff is introduced, and from which said polymerfluff can be transferred via rotary feeder 10′. Rotary feeder 10′ isfluidly connected with upstream vessel UV via upstream vessel outletline 53, and, via rotary feeder outlet line 54, with a downstream vesselDV to which the polymer fluff is to be transferred. In embodiments, theupstream vessel UV may be positioned directly above the herein-disclosedrotary feeder comprising cleaning nozzles. In such embodiments, gravitymay serve to feed material to the rotary feeder.

As will be described in more detail with reference to FIGS. 3-5 , thefluff-containing upstream vessel UV from which polymer fluff will betransferred via rotary feeder 10′ can comprise a flash unit, a purgecolumn, a polymer product storage silo, a degasser (e.g., a primarydegasser, a secondary degasser, a tertiary degasser), an extruder feedtank or vessel, or a combination thereof.

In embodiments, the upstream vessel UV is configured to remove residualhydrocarbon from a product polymer fluff or flake. For example, theupstream vessel UV may, in embodiments, be a degasser, a flash unit, ora purge column that is located downstream of the polymerizationreactor(s) 40 and is configured to remove volatiles (e.g., diluent) fromthe polymer product. In such embodiments, a line 51 may be configured tointroduce a gas (e.g., a purge gas) into upstream vessel UV, a line 52may be configured for the removal of an off-gas (and associatedvolatiles) from upstream vessel UV, or both.

Any suitable technique may be used to separate the polymerizationproduct into solid polymer and gases. For example, the upstream vesselUV or a separation vessel 50A (described hereinbelow with reference tothe embodiment of FIG. 5 ) may comprise a vapor-liquid separator.Suitable embodiments of a vapor-liquid separator may include adistillation column, a flash tank, a filter, a membrane, a reactor, anabsorbent, an adsorbent, a molecular sieve, a cyclone, or a combinationthereof. In an embodiment, the upstream vessel comprises a flash tank.Not seeking to be bound by theory, such a flash tank may comprise avessel configured to vaporize and/or remove low vapor pressurecomponents from a fluid that is high temperature, high pressure, orboth.

In embodiments, as described in further detail hereinbelow withreference to the embodiment of FIG. 4 , polymerization reactor 40comprises one or more gas phase polymerization reactors, and upstreamvessel UV comprises a degasser, for example, a primary, secondary, ortertiary degasser. In other embodiments, as described in further detailhereinbelow with reference to the embodiment of FIG. 5 , polymerizationreactor 40 comprises one or more slurry loop polymerization reactors,and the upstream vessel UV comprises a flash unit or a purge column.

In embodiments, upstream vessel UV is configured for the storage ofproduct polymer fluff. For example, in embodiments, as described in moredetail with reference to the embodiments of FIGS. 3 and 5 , upstreamvessel UV may comprise a fluff silo or storage tank, an extruder feedtank, or the like.

As indicated in the embodiment of FIG. 2 , rotary feeder 10′ ispositioned flow-wise between upstream vessel UV and downstream vesselDV, and is operable to transfer material therebetween. In embodiments,the downstream vessel DV may be positioned directly below theherein-disclosed rotary feeder comprising cleaning nozzles. Thedownstream vessel can be any vessel into which the material in upstreamvessel UV, from which the material to be transferred is introduced intorotary feeder 10′, is to be transferred. By way of non-limiting example,the downstream vessel DV can be a fluff silo or storage tank, a feedtank (e.g., an extruder feed tank or extruder hopper), a purge tank, adegasser, or the like. In embodiments, a rotary feeder of thisdisclosure is utilized to transfer product polymer fluff from anupstream vessel comprising a flash unit to a downstream vesselcomprising a purge column; in embodiments, a rotary feeder of thisdisclosure is utilized to transfer product polymer fluff from anupstream vessel comprising a purge column to a downstream vesselcomprising a fluff silo, an extruder feed tank, an extruder hopper, oran extruder; in embodiments, a rotary feeder of this disclosure isutilized to transfer product polymer fluff from an upstream vesselcomprising a degasser (e.g., a primary or secondary degasser) to adownstream vessel comprising another degasser (e.g., a secondary ortertiary degasser); in embodiments, a rotary feeder of this disclosureis utilized to transfer product polymer fluff from an upstream vesselcomprising a degasser to a downstream vessel comprising a fluff silo, anextruder feed tank, an extruder hopper, or an extruder. The ‘cleaning’gas injected via injection nozzles 36 may be transferred along with thetransferred material into the downstream vessel. In embodiments, thedownstream vessel DV may comprise a gas outlet (such as 52A′/52A″) viawhich cleaning gas transferred thereto along with the transferredmaterial from the rotary feeder may be removed from the system. Product(e.g., polymer pellets) may be removed from the system via productoutlet line 55.

Another system of this disclosure will now be described with referenceto FIG. 3 . System 100A of FIG. 3 comprises polymerization reactor 40,degasser(s) or separator(s) 50A, fluff silo 50B, extruder feed tank 50C,and an extruder or extruder hopper 50D. Polymerization reactor(s) 40 areas described hereinabove with reference to the embodiment of FIG. 2 .Degasser(s) 50A are configured for the removal of hydrocarbons from thepolymer product, and may be any degasser(s) known in the art. Inembodiments, a gas inlet line 51A is operable to introduce a strippinggas, such as, without limitation, fresh nitrogen, recycled nitrogen, ora combination thereof into degasser(s) 50A. In embodiments, a gas outletline 52A is fluidly connected with degasser(s) 50A, and configured forthe removal of stripped hydrocarbons and stripping gas from degasser(s)50A. Fluff silo or storage tank 50B may be any storage vessel operablefor the storage of polymer fluff or flake. Extruder feed tank 50C may beany vessel operable for the storage of polymer fluff for introductioninto a downstream extruder. In embodiments, various components (e.g.,one or more additives) may be combined with the polymer fluff inextruder feed tank 50C, and subsequently extruded therewith. Unit 50Dmay be an extruder as known in the art to be operable to extrude polymerpellets from a feed comprising the polymer fluff and optionally variousadditives. In embodiments, unit 50D is an extruder hopper, as known inthe art. One or more lines may be fluidly connected with unit 50D, andconfigured for the introduction of various components (e.g., additives)into extruder or extruder hopper 50D, whereby said components cansubsequently be extruded with the polymer fluff. Such additives areknown to those of skill in the art, and will not be expounded upon here.

A rotary feeder 10A according to this disclosure may be positionedbetween an upstream degasser 50A, with which it is fluidly connected viadegasser outlet line 53A, and a downstream vessel comprising a fluffsilo 50B. Rotary feeder 10A may be configured to transfer polymer fluffproduced in polymerization reactor 40, transferred to degasser(s) 50Avia polymerization reactor outlet line 45A, and degassed in degasser 50Ato downstream fluff silo 50B via rotary feeder outlet line 54A and fluffsilo feed line 45B. Alternatively or additionally, rotary feeder 10A maybe configured to transfer polymer fluff produced in polymerizationreactor 40 and degassed in degasser 50A to an extruder feed tank 50C viarotary feeder outlet line 54A and extruder feed tank inlet line 45C.Alternatively, or additionally, a rotary feeder 10B according to thisdisclosure may be positioned between fluff silo or storage tank 50B,with which it is fluidly connected via fluff silo outlet line 53B, and adownstream vessel comprising an extruder feed tank 50C, with which it isconnected via rotary feeder outlet line 54B and extruder feed tank inletline 45C. In this manner, rotary feeder 10B may be configured totransfer polymer fluff stored in fluff silo 50B to a downstream extruderfeed tank 50C (or, not shown in FIG. 3 , to a downstream extruder hopperor extruder 50D). Alternatively or additionally, a rotary feeder 10Caccording to this disclosure may be positioned between an upstreamvessel comprising extruder feed tank 50C, with which it is fluidlyconnected via extruder feed tank outlet line 53C, and a downstreamvessel comprising an extruder hopper or extruder 50D, with which it isconnected via rotary feeder outlet line 54C. In this manner, rotaryfeeder 10C may be configured to transfer polymer fluff stored inextruder feed tank 50C to a downstream extruder hopper or extruder 50D.Extruded product comprising pelletized polymer may be removed fromsystem 100A via product outlet line 55.

As noted hereinabove, a system according to this disclosure may compriseone or more degassers. A system of this disclosure comprising multipledegassers will now be described with reference to FIG. 4 . System 100Bof the embodiment of FIG. 4 comprises polymerization reactor 40, primarydegasser 50A, secondary degasser 50A′, and tertiary degasser 50A″.Polymerization reactor(s) 40 are as described hereinabove with referenceto the embodiment of FIG. 2 . As with degasser(s) 50A describedhereinabove with reference to the embodiment of FIG. 3 , primary,secondary, and tertiary degassers 50A, 50A′, and 50A″ are configured forthe removal of hydrocarbons from the polymer product, and may be anydegasser(s) known in the art. In embodiments, a gas inlet line 51A,51A′, 51A″ is operable to introduce a stripping gas, such as, withoutlimitation, fresh nitrogen, recycled nitrogen, or a combination thereofinto degasser 50A, 50A′, 50A″, respectively. In embodiments, a gasoutlet line 52A, 52A′, 52A″ is fluidly connected with degasser 50A,50A′, 50A″, respectively, and is configured for the removal of strippedhydrocarbons and stripping gas therefrom.

A rotary feeder 10A may be positioned downstream of primary degasser50A, and fluidly connected therewith via primary degasser outlet line53A, whereby primarily degassed polymer fluff can be introduced thereto.Rotary feeder 10A may be configured for the transfer of primarilydegassed polymer fluff from primary degasser 50A into a downstreamvessel, such as secondary degasser 50A′, via line 54A. Alternatively oradditionally, a rotary feeder 10A′ may be positioned downstream ofsecondary degasser 50A′, and fluidly connected therewith via secondarydegasser outlet line 53A′, whereby secondarily degassed polymer fluffcan be introduced thereto. Rotary feeder 10A′ may be configured for thetransfer of secondarily degassed polymer fluff from secondary degasser50A′ into a downstream vessel, such as tertiary degasser 50A″, via line54A′. Alternatively or additionally, a rotary feeder 10A″ may bepositioned downstream of tertiary degasser 50A″, and fluidly connectedtherewith via tertiary degasser outlet line 53A″, whereby tertiarilydegassed polymer fluff can be introduced thereto. Rotary feeder 10A″ maybe configured for the transfer, via line 54A″, of tertiarily degassedpolymer fluff from tertiary degasser 50A″ into a downstream vessel, suchas, for example, a fluff silo or storage tank, an extruder feed tank, anextruder hopper, or an extruder, as described hereinabove with referenceto the embodiment of FIG. 3 .

As noted hereinabove, a system of this disclosure may comprise multiplepolymerization reactors, a flash unit, a purge column, or a combinationthereof, in addition to a rotary feeder according to this disclosure.Such a system will now be described with reference to FIG. 5 . System100C of FIG. 5 comprises first polymerization reactor 40A, secondpolymerization reactor 40B, flash unit 50A, purge column 50A′, fluffsilo or storage tank 50B, extruder feed tank 50C, extruder hopper 50D,and extruder 50D′.

Polymerization reactors 40A and 40B can be any suitable polymerizationreactors, as described hereinabove with reference to the embodiment ofFIG. 2 . In embodiments, polymerization reactors 40A and 40B areselected from gas phase polymerization reactors and loop slurrypolymerization reactors. In embodiments, first polymerization reactor40A and second polymerization reactor 40B are loop slurry reactors.Catalyst line 43A may be operable to introduce polymerization catalyst,as described hereinabove with reference to the embodiment of FIG. 2 ,from catalyst storage unit 42A into first polymerization reactor 40A.One or more feed lines 41A may be configured for the introduction of apolymerization feed as described hereinabove with reference to theembodiment of FIG. 2 into first polymerization reactor 40A. Inembodiments, a pump P1 may be configured to circulate the contents offirst polymerization reactor 40A (e.g., a slurry loop polymerizationreactor). Line 41B may fluidly connect first polymerization reactor 40Aand second polymerization reactor 40B, whereby a polymer product offirst polymerization reactor 40A can be introduced into secondpolymerization reactor 40B. In embodiments, another line(s) 41B may beconfigured for the introduction of additional feed components intosecond polymerization reactor 40B. In embodiments, a catalyst feed line,similar to catalyst feed line 43A, and a catalyst storage unit similarto catalyst storage unit 42A may be configured for the introduction ofcatalyst (which may be the same or different from that introduced intofirst polymerization reactor 40A) into second polymerization reactor40B. In embodiments, a pump P2 may be configured to circulate thecontents of second polymerization reactor 40B (e.g., a slurry looppolymerization reactor).

A line 45A may fluidly connect second polymerization reactor 40B withseparation vessel 50A, which may be a flash unit or chamber. Athrottling valve 44 may be positioned on line 45A and operable tocontrol the rate of flow out of second polymerization reactor 40B. Inembodiments, throttling valve 44 may be a plug valve or ball valve, asdescribed for example in U.S. Pat. No. 7,109,290, the disclosure ofwhich is hereby incorporated herein by reference in its entirety for allpurposes not contrary to this disclosure, or a continuous takeoff valve,as described for example in U.S. Pat. No. 8,921,498, the disclosure ofwhich is hereby incorporated herein by reference in its entirety for allpurposes not contrary to this disclosure. A flashline heater 46, asdescribed for example in U.S. Pat. No. 8,921,498, may be positioned online 45A.

Flash chamber 50A receives polymer from second polymerization reactor40B via line 45A, which may be a high pressure line. Flash chamber 50Agenerally removes diluent, solvent, other volatiles, or a combinationthereof from the polymer fluff/solids. The volatiles exit the top of theflash chamber 50A via gas outlet line 52A, and may be recycled, inembodiments, for reuse in polymerization reactor 40A, 40B, or both.Depending on the type of polymerization reactor involved, and processdesign, the flash chamber 50A may also be described as a high pressureflash chamber, primary degasser, or powder separator.

In an embodiment, polymer (also referred to as “polymer fluff” or“polymer solids”) is transferred from second polymerization reactor 40Bthrough line 45A to flash chamber 50A via a first pressure differentialbetween the operating pressures of the second polymerization reactor 40Band the flash chamber 50A, as described in U.S. Pat. No. 7,109,289. Theoperating pressure of the flash chamber 50A may affect the transport ofpolymer between flash chamber 50A and purge column 50A′, as described inU.S. Pat. No. 7,109,289. In an embodiment, flash chamber 50A is operatedat a pressure of from about 50 psig (0.34 MPa) to about 500 psig (3.4MPa); alternatively, from about 130 psig (0.9 MPa) to about 190 psig(1.3 MPa).

As noted hereinabove, flash chamber 50A is operable to separatevolatiles remaining with the polymer solids from second polymerizationreactor 40B from the solids. Recovered volatiles may be directed fromthe top of the flash chamber 50A and gas outlet line 52A to recycle.Valve 10A may be fluidly connected with flash chamber 50A via flashchamber outlet line 53A, and may be operable to control solids flow fromflash chamber 50A. Valve 10A may be, in embodiments, a rotary feedercomprising cleaning nozzles according to this disclosure. A line 54A(which may be a low pressure line, in embodiments) may be configured tocarry polymer solids from flash chamber 50A to a purge column 50A′.

Purge column 50A′ receives polymer from flash chamber 50A via line 54A.In an embodiment, purge column 50A′ is operated at a pressure of fromabout 150 psig (1 MPa) to about −5 psig (−0.03 MPa); alternatively, fromabout 25 psig (0.17 MPa) to about 0 psig (0 MPa); alternatively fromabout 10 psig (0.07 MPa) to about 2 psig (0.01 MPa). Purge column 50A′generally employs a stripping or purge gas, such as nitrogen, fed nearthe bottom of purge column 50A′. For example, line 51A′ may beconfigured to supply purge gas (e.g., nitrogen) to purge column 50A′.Within purge column 50A′, purge gas supplied by line 51A′ furtherremoves volatiles (e.g., diluent isobutane) from the polymer solids inpurge column 50A′. Line 52A′ is fluidly connected with purge column50A′, and configured to convey the supplied purge gas and displacedvolatiles from the top of purge column 50A′. The purge gas may bepurified of volatiles and recycled to the purge column via a purgegas—solvent/diluent recovery unit, such as, for example, an isobutanenitrogen recovery unit (IBNU). The purged volatiles (e.g., isobutane)exit purge column 50A′ along with the purge or carrier gas via line52A′. Apparatus may be included in system 100C to remove volatiles fromthe purge gas (e.g., nitrogen) via, for example, compression,condensation, absorption, adsorption, a membrane, combinations thereofor other separation means. The system may be configured such that therecovered purge gas may be recycled to purge column 50A′ via line 51A′,to further purge residual volatiles from polymer solids.

In an embodiment, as described in U.S. Pat. No. 7,109,290, purge column50A′ combines the functions of a purge column and extruder feed tank:recovering volatiles, providing surge volume capacity, and feedingpolymer to an extruder. Thus, in embodiments, purge column 50A′comprises the functions of a disengaging vessel, a purge column, and anextruder feed tank. In embodiments, purge column 50A′ is separate froman extruder feed tank (such as extruder feed tank 50C in the embodimentof FIG. 5 ), and gravity may be employed to move polymer from purgecolumn 50A′ to a downstream vessel, such as an extruder feed tank.

In embodiments, purge column 50A′ is fluidly connected via purge columnoutlet line 53A′ with rotary feeder 10A′, which may be a rotary feedercomprising cleaning nozzles according to this disclosure. Rotary feeder10A′ may be fluidly connected via rotary feeder outlet line 54A′ with adownstream vessel into which polymer fluff from purge chamber 50A′ isintroduced via rotary feeder 10A′. The downstream vessel may be a fluffsilo or storage tank, an extruder feed tank, an extruder hopper, or anextruder. For example, as in the embodiment of FIG. 5 , rotary feederoutlet line 54A′ and fluff silo inlet line 45B may fluidly connectrotary feeder 10A′ with fluff silo 50B, while rotary feeder outlet line54A′ and extruder feed tank inlet line 45C may fluidly connect rotaryfeeder 10A′ with extruder feed tank 50C. Alternatively or additionally,a rotary feeder 10B according to this disclosure may fluidly connectfluff silo or storage tank 50B outlet line 53B with extruder feed tank50C via extruder feed tank inlet line 45C, whereby polymer fluff may beintroduced from fluff silo or storage tank 50B into extruder feed tank50C. Alternatively or additionally, a rotary feeder 10C according tothis disclosure may fluidly connect extruder feed tank 50C via extruderfeed tank outlet line 53C with extruder hopper 50D (or directly withextruder 50D′, not shown in the embodiment of FIG. 5 ) via extruderhopper inlet line 54C, whereby polymer fluff may be introduced fromextruder feed tank 50C into extruder feed hopper 50D (or directly intoextruder 50D′, not shown in the embodiment of FIG. 5 ). In embodiments,an extruder hopper outlet line 54C′ may fluidly connect extruder hopper50D with extruder 50D′, and an extruder or product outlet line 55 may beconfigured for the removal of polymer product (e.g., polymer pellets)from extruder 50D′.

As noted hereinabove with reference to the embodiment of FIG. 3 ,various components (e.g., one or more additives) may be combined withthe polymer fluff in one or more of extruder feed tank 50C, extruderhopper 50D, and extruder 50D′, and subsequently extruded therewith. Forexample, in the embodiment of FIG. 5 , a line 56 is configured for theintroduction of various components (e.g., additives such as stabilizers)into extruder hopper 50D, whereby said components can subsequently beextruded with the polymer fluff. As noted above, such additives areknown to those of skill in the art, and will not be expounded upon here.

In embodiments, first and second polymerization reactors 40A and 40B areloop slurry reactors comprising ethylene monomer, 1-hexene comonomer,and isobutane as solvent. The slurry loop reactors may operate at apressure of about 650 psig (4.5 MPa), the flash chamber 50A may operateat a pressure of about 135 psig (0.9 MPa), and the purge column 50A′ mayoperate at a pressure of from greater than about 0 psig (0 MPa) to about5 psig (0.03 MPa).

In embodiments, the gas in line 52, 52A, 52A′, 52A″ may comprise one ormore of hydrogen, nitrogen, methane, ethylene, ethane, propylene,propane, butane, isobutane, pentane, hexane, hexene-1, and heavierhydrocarbons. In embodiments, ethylene may be present in a range of fromabout 0.1% to about 15%, alternatively, from about 1.5% to about 5%,alternatively, about 2% to about 4% by total weight of the line. Ethanemay be present in a range of from about 0.001% to about 4%,alternatively, from about 0.2% to about 0.5% by total weight of theline. Isobutane may be present in a range from about 80% to about 98%,alternatively, from about 92% to about 96%, alternatively, about 95% bytotal weight of the line.

Although described as rotary feeders comprising cleaning nozzlesaccording to this disclosure, it is to be understood that a system ofthis disclosure may comprise one or more rotary feeders comprisingcleaning nozzles, and other conventional rotary feeders (i.e., rotaryfeeders not comprising cleaning nozzles as described herein). Forexample, a system such as shown in the embodiment of FIG. 3 , maycomprise one or more rotary feeders as described herein; that is, one ormore of rotary feeders 10A, 10B, and 10C may be a rotary feedercomprising cleaning nozzles as described herein, while conventionalrotary feeders that do not contain cleaning nozzles as described herein,or other transfer apparatus (e.g., gravity, pressure differential,valves, etc.), may be utilized for the remaining transfer(s). Similarly,a system such as shown in the embodiment of FIG. 4 , may comprise one ormore rotary feeders as described herein; that is, one or more of rotaryfeeders 10A, 10A′, and 10A″ may be a rotary feeder comprising cleaningnozzles as described herein, while conventional rotary feeders that donot contain cleaning nozzles as described herein, or other transferapparatus, may be utilized for the remaining transfer(s). Similarly, asystem such as shown in the embodiment of FIG. 5 , may comprise one ormore rotary feeders as described herein; that is, one or more of rotaryfeeders 10A, 10A′, 10B, and 10C may be a rotary feeder comprisingcleaning nozzles as described herein, while conventional rotary feedersthat do not contain cleaning nozzles as described herein, or othertransfer apparatus, may be utilized for the remaining transfer(s).

Also disclosed herein is a method of transferring material utilizing arotary feeder comprising cleaning nozzles according to this disclosure.The herein-disclosed method comprises introducing a polymer fluff into arotary valve as described herein, and injecting gas into the rotaryfeeder via the number of injection nozzles. In embodiments, theherein-disclosed rotary feeder comprises a stationary, cylindricalhousing having disposed therein a number of injection nozzles, andwithin which rotate a plurality of vanes about a central axis, whereinthe housing extends a width along the central axis, wherein each of thevanes has a length along the central axis, and wherein the injectionnozzles are positioned across the width of the housing, such that aspray pattern of a gas injected via the number of injection nozzlesspans substantially the entire length of the vanes.

The method may comprise injecting a gas substantially continuouslyduring operation of the rotary feeder, or via pulsed injection. Theinjection nozzles may be pulsed simultaneously, sequentially, or acombination thereof. For example, multiple injection nozzles may bepulsed together, in sequence with others of the injection nozzles. Byway of non-limiting example, injection nozzles 1 and 3 of the embodimentof FIG. 1B may be pulsed together in series with injection nozzles 2 and4, which may be also be pulsed together, or the like. In embodiments,the injection nozzles are pulsed in series. In embodiments, theinjection nozzles are pulsed one at a time in series. For example,injection nozzles 1 to 4 of the embodiment of FIG. 1B may be pulsed inthe order 1, 2, 3, 4. Alternatively, they are pulsed out of order, e.g.,in the order 1, 3, 2, 4 or 1, 4, 2, 3, or the like. The injectionnozzles may be pulsed in series once every 3 to 30, 3 to 10, or 3 to 5seconds, or continuously. For example, injection nozzles 1 to 4 of theembodiment of FIG. 1B may be pulsed in series (e.g., injection nozzle 1,then 2, then 3, then 4) for a duration of from about 3 to about 5seconds per nozzle, and the entire series of nozzles may be pulsed onceevery 3 to 30, 3 to 10, or 3 to 5 seconds. In embodiments, injectionnozzles 36 cycle through pulsing for a pulsing time period (e.g., 1, 2,3 minutes) every so often (e.g., every 3, 5, or 7 minutes), with eachnozzle opening for about 3-5 seconds at a time during the pulsing timeperiod.

Via utilization of a rotary feeder comprising cleaning nozzles accordingto this disclosure, a rate of polymer buildup on the vanes of the rotaryfeeder may be reduced relative to a rate of polymer buildup on vanes ofa rotary feeder not comprising said injection nozzles. Althoughdependent on the application, and without wishing to be limited, inembodiments, the rate of polymer buildup is decreased by at least 10,15, or 20%.

During operation, the rotation speed of a rotary feeder is generallyincreased if there is buildup of material on the vanes thereof, in orderto maintain a desired production rate. However, when the volumetransferred via the rotary feeder is insufficient to provide sufficientmaterial to meet a desired production rate even at maximum rotationspeed, production may be interrupted so that the rotary feeder can becleaned (e.g., mechanically cleaned via scraping, abrasive blasting,etc.). Desirably, utilization of a rotary feeder comprising cleaningnozzles according to this disclosure enables a longer time on streambefore cleaning is deemed necessary. In embodiments, an amount of freeor transport volume (i.e., volume not occupied by undesired polymerbuildup) present in wedge volumes WV necessary to provide a desiredpolymer outlet rate can be maintained for an increased time of operationrelative to a rotary feeder not comprising injection nozzles 36. Theincreased time may, in embodiments, be at least an additional 1, 5, 10,20, or 30 days, or 1, 2, or 3 months.

A rotary feeder comprising specialized injection nozzles, as describedherein, may enable injection of gas into an interior space of the rotaryfeeder, whereby buildup of material, such as polymer fluff, on interiorsurfaces, including vanes of the rotary feeder, can be decreased. Inthis manner, such a rotary feeder may more effectively maintainefficient transfer of material, such as polymer, from the feederrelative to a rotary feeder absent such injection nozzles. Althoughtubing could be utilized for the introduction of gas into the rotaryfeeder, in embodiments, incorporation of specialized nozzles, which mayprovide a desired (e.g., fan type) spray pattern, may more effectivelyclean the interior surfaces (e.g., the rotating vanes) of the rotaryfeeder.

Additional Disclosure

The particular embodiments disclosed above are illustrative only, as thepresent disclosure may be modified and practiced in different butequivalent manners apparent to those skilled in the art having thebenefit of the teachings herein. Furthermore, no limitations areintended to the details of construction or design herein shown, otherthan as described in the claims below. It is therefore evident that theparticular illustrative embodiments disclosed above may be altered ormodified and all such variations are considered within the scope andspirit of the present disclosure. Alternative embodiments that resultfrom combining, integrating, and/or omitting features of theembodiment(s) are also within the scope of the disclosure. Whilecompositions and methods are described in broader terms of “having”,“comprising,” “containing,” or “including” various components or steps,the compositions and methods can also “consist essentially of” or“consist of” the various components and steps. Use of the term“optionally” with respect to any element of a claim means that theelement is required, or alternatively, the element is not required, bothalternatives being within the scope of the claim.

Numbers and ranges disclosed above may vary by some amount. Whenever anumerical range with a lower limit and an upper limit is disclosed, anynumber and any included range falling within the range is specificallydisclosed. In particular, every range of values (of the form, “fromabout a to about b,” or, equivalently, “from approximately a to b,” or,equivalently, “from approximately a-b”) disclosed herein is to beunderstood to set forth every number and range encompassed within thebroader range of values. Also, the terms in the claims have their plain,ordinary meaning unless otherwise explicitly and clearly defined by thepatentee. Moreover, the indefinite articles “a” or “an”, as used in theclaims, are defined herein to mean one or more than one of the elementthat it introduces. If there is any conflict in the usages of a word orterm in this specification and one or more patent or other documents,the definitions that are consistent with this specification should beadopted.

The following are nonlimiting, specific embodiments in accordance withthe present disclosure:

-   -   A: A rotary feeder comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein the housing extends a width along the central axis,        wherein each of the vanes has a length along the central axis,        and wherein the injection nozzles are positioned across the        width of the housing, such that a spray pattern of a gas        injected via the number of injection nozzles spans substantially        the entire length of the vanes.    -   B: A system comprising: one or more polymerization reactors        configured to produce a product polymer; a vessel configured to        receive the polymer product produced in the one or more        polymerization reactors, wherein the vessel comprises a flash        unit, a purge column, a polymer product storage silo, an        extruder, a primary degasser, a secondary degasser, an extruder        feed tank, or a combination thereof; and a rotary feeder        comprising a stationary, cylindrical housing having disposed        therein a number of injection nozzles, and within which rotate a        plurality of vanes about a central axis, wherein the housing        defines an inlet and an outlet, and extends a width along the        central axis, wherein each of the vanes has a length along the        central axis, and wherein the injection nozzles are positioned        across the width of the housing, such that a spray pattern of a        gas injected via the number of injection nozzles spans        substantially the entire length of the vanes, wherein the rotary        feeder is downstream of the vessel and fluidly connected        therewith, via the inlet of the rotary feeder, whereby product        polymer is introduced thereto.    -   C: A method comprising: introducing a polymer fluff into a        rotary valve comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein the housing extends a width along the central axis,        wherein each of the vanes has a length along the central axis,        and wherein the injection nozzles are positioned across the        width of the housing, such that a spray pattern of a gas        injected via the number of injection nozzles spans substantially        the entire length of the vanes; and injecting gas into the        rotary feeder via the number of injection nozzles.    -   D: A rotary feeder comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein pairs of adjacent vanes of the plurality of vanes define        wedge volumes, wherein the housing extends a width along the        central axis, wherein each of the vanes has a length along the        central axis, and wherein the injection nozzles are positioned        across the width of the housing, such that a spray pattern of a        gas injected via the number of injection nozzles spans        substantially the entire length of the vanes.    -   E: A rotary feeder comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein the housing extends a width along the central axis,        wherein each of the vanes has a length along the central axis,        wherein the injection nozzles are positioned across the width of        the housing, such that a spray pattern of a gas injected via the        number of injection nozzles spans substantially the entire        length of the vanes, and wherein each of the number of injection        nozzles is located at a position along a circumference of the        housing that is in the range of from about 50° to about 170°        from an inlet of the rotary feeder, along a direction of        rotation of the plurality of vanes.    -   F: A rotary feeder comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein the housing extends a width along the central axis from        end walls thereof, wherein each of the vanes extends a length        along the central axis, wherein the length each of the plurality        of vanes extends along the central axis is slightly less than        the width of the housing along the central axis, such that the        each of the plurality of vanes extends almost to the end walls        of the housing and can rotate freely within the housing, and        wherein the injection nozzles are positioned across the width of        the housing, such that a spray pattern of a gas injected via the        number of injection nozzles spans substantially the entire        length of the vanes.    -   G: A rotary feeder comprising: a stationary, cylindrical housing        having disposed therein a number of injection nozzles, and        within which rotate a plurality of vanes about a central axis,        wherein the stationary, cylindrical housing defines an inlet and        an outlet, wherein the inlet is positioned at a top of the        housing, and the outlet is positioned at a bottom of the        housing, wherein the housing extends a width along the central        axis, wherein each of the vanes has a length along the central        axis, and wherein the injection nozzles are positioned across        the width of the housing, such that a spray pattern of a gas        injected via the number of injection nozzles spans substantially        the entire length of the vanes.

Each of embodiments A, B, C, D, E, F, and G may have one or more of thefollowing additional elements. Element 1: wherein the length of eachvane of the plurality of vanes is in the range of from about 12 inches(30.5 cm) to about 20 inches (50.8 cm). Element 2: wherein thestationary, cylindrical housing further defines an inlet and an outlet,optionally wherein the inlet is positioned at a top of the housing, andoptionally wherein each of the number of injection nozzles is located ata position along a circumference of the housing that is in the range offrom about 90° to about 160°, or from about 50° to about 170°, from theinlet, along a direction of rotation of the plurality of vanes. Element3: wherein the number of injection nozzles are located in a line acrossthe width of the housing. Element 4: comprising eight vanes. Element 5:wherein the number of injection nozzles are positioned substantiallyequidistantly apart across the width of the housing. Element 6: whereina center-to-center distance between adjacent injection nozzles is equalto the width of the housing divided by the number of injection nozzles.Element 7: wherein a center-to center-distance between adjacentinjection nozzles is in the range of from about 2 inches (50.8 mm) toabout 4 inches (10.16 cm). Element 8: wherein a first injection nozzleand a last injection nozzle across the width of the housing are locateda distance along the central axis from an end of the housing closestthereto that is about equal to the width of the housing divided by twotimes the number of injection nozzles. Element 9: wherein the number ofinjection nozzles is in the range of from about 4 to about 5. Element10: wherein each of the number of injection nozzles is configured toprovide a spray pattern selected from fan patterns, air-knife patterns,or combinations thereof. Element 11: wherein each of the number ofinjection nozzles is configured to provide a fan spray pattern. Element12: wherein a spray pattern provided by each of the number of injectionnozzles comprises a spray angle in the range of from about 15° to about120°. Element 13: wherein each of the number of spray nozzles is fluidlyconnected with a gas source via a gas feed line. Element 14: whereineach of the number of spray nozzles is fluidly connected with a gassource via a gas feed line, optionally having an inside diameter in therange of from about ¼ inch (6.4 mm) to about ½ inch (12.7 mm). Element15: wherein each of the number of spray nozzles is fluidly connectedwith a gas source via a gas feed line, and wherein the gas sourceprovides gas at a pressure in the range of from about 40 psi (0.28 MPa)to about 60 psi (0.41 MPa). Element 16: wherein the injection nozzlesare positioned across the width of the housing such that the spraypattern of each of the number of injection nozzles overlaps the spraypattern of at least one adjacent nozzle. Element 17: wherein a spraypattern of each of the number of injection nozzles overlaps, at thevanes, a spray pattern of at least one adjacent nozzle by at least 10%.Element 18: wherein each of the number of injection nozzles is aone-piece construction. Element 19: wherein each of the number ofinjection nozzles is made of brass, 303 stainless steel, 316 stainlesssteel, polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), or acombination thereof. Element 20: further comprising injecting gassubstantially continuously during operation of the rotary feeder, or viapulsed injection. Element 21: further comprising pulsing the number ofinjection nozzles simultaneously, sequentially, or a combinationthereof. Element 22: wherein the injection nozzles are pulsed in series.Element 23: wherein the injection nozzles are pulsed in series for aboutone minute every five minutes, with each nozzle pulsed for 2 to 5seconds; or continuously. Element 24: wherein a rate of polymer buildupon the vanes of the rotary feeder is reduced relative to a rate ofpolymer buildup on vanes of a rotary feeder not comprising saidinjection nozzles. Element 25: wherein the rate of polymer buildup isdecreased by at least 10%. Element 26: wherein an amount of polymer fillof wedge volumes defined by the plurality of vanes to provide a desiredpolymer outlet rate can be maintained for an increased time of operationrelative to a rotary feeder not comprising said injection nozzles.Element 27: wherein an increased time comprises at least an additional24 hours. Element 28: wherein the number of injection nozzles arepositioned such that the wedge volumes defined by the pairs of adjacentvanes are substantially full when they rotate past the location of thenumber of injection nozzles within the housing. Element 29: wherein theinlet is positioned at a top of the housing, and/or wherein the outletis positioned at a bottom of the housing. Element 30: wherein the lengthof each of the plurality of vanes is slightly less than the width of thehousing along the central axis, such that the each of the plurality ofvanes extends almost to the end walls of the housing and can rotatefreely within the housing. Element 31: wherein the length of each of theplurality of vanes is less than 1.0, 0.5, 0.25, 0.15, 0.1 or 0.05 inch(25.4, 12.7, 6.35, 3.81, 2.54, or 1.27 mm)) less than the width of thehousing. Element 32: wherein pairs of adjacent vanes of the plurality ofvanes define wedge volumes.

While preferred embodiments of the invention have been shown anddescribed, modifications thereof can be made by one skilled in the artwithout departing from the teachings of this disclosure. The embodimentsdescribed herein are exemplary only, and are not intended to belimiting. Many variations and modifications of the invention disclosedherein are possible and are within the scope of the invention.

Numerous other modifications, equivalents, and alternatives, will becomeapparent to those skilled in the art once the above disclosure is fullyappreciated. It is intended that the following claims be interpreted toembrace all such modifications, equivalents, and alternatives whereapplicable. Accordingly, the scope of protection is not limited by thedescription set out above but is only limited by the claims whichfollow, that scope including all equivalents of the subject matter ofthe claims. Each and every claim is incorporated into the specificationas an embodiment of the present invention. Thus, the claims are afurther description and are an addition to the detailed description ofthe present invention. The disclosures of all patents, patentapplications, and publications cited herein are hereby incorporated byreference, to the extent that they provide exemplary, procedural orother details supplementary to those set forth herein.

What is claimed is:
 1. A rotary feeder comprising: a stationary,cylindrical housing having disposed therein a number of injectionnozzles, and within which rotate a plurality of vanes about a centralaxis, wherein pairs of adjacent vanes of the plurality of vanes definewedge volumes, wherein the housing extends a width along the centralaxis, wherein each of the vanes has a length along the central axis, andwherein the injection nozzles are positioned across the width of thehousing, such that a spray pattern of a gas injected via the number ofinjection nozzles spans substantially the entire length of the vanes,wherein each of the number of injection nozzles is fluidly connectedwith a gas source via a gas feed line.
 2. The rotary feeder of claim 1,wherein the number of injection nozzles are positioned such that thewedge volumes defined by the pairs of adjacent vanes are substantiallyfull when they rotate past the location of the number of injectionnozzles within the housing.
 3. The rotary feeder of claim 2, whereineach of the number of injection nozzles is located at a position along acircumference of the housing that is in the range of from about 50° toabout 170° from an inlet of the rotary feeder, along the direction ofrotation of the plurality of vanes.
 4. The rotary feeder of claim 1,wherein the stationary, cylindrical housing defines an inlet and anoutlet of the rotary feeder, wherein the inlet is positioned at a top ofthe housing, and the outlet is positioned at a bottom of the housing. 5.The rotary feeder of claim 1, wherein the length of each of theplurality of vanes is slightly less than the width of the housing alongthe central axis, such that the each of the plurality of vanes extendsalmost to the end walls of the housing and can rotate freely within thehousing.
 6. The rotary feeder of claim 1, wherein the number ofinjection nozzles are located in a line across the width of the housing.7. The rotary feeder of claim 6, wherein the number of injection nozzlesare positioned substantially equidistantly apart across the width of thehousing.
 8. The rotary feeder of claim 7, wherein a center-to-centerdistance between adjacent injection nozzles is equal to the width of thehousing divided by the number of injection nozzles.
 9. The rotary feederof claim 1, wherein a first injection nozzle and a last injection nozzleacross the width of the housing are located a distance along the centralaxis from an end of the housing closest thereto that is about equal tothe width of the housing divided by two times the number of injectionnozzles.
 10. The rotary feeder of claim 1, wherein each of the number ofinjection nozzles is configured to provide a spray pattern selected fromfan patterns, air-knife patterns, or combinations thereof.
 11. Therotary feeder of claim 10, wherein each of the number of injectionnozzles is configured to provide a fan spray pattern, wherein a spraypattern provided by each of the number of injection nozzles comprises aspray angle in the range of from about 15° to about 120°.
 12. The rotaryfeeder of claim 1, wherein the number of injection nozzles arepositioned across the width of the housing such that the spray patternof each of the number of injection nozzles overlaps the spray pattern ofat least one adjacent nozzle.
 13. The rotary feeder of claim 1, wherein,of the number of injection nozzles, a first injection nozzle and a lastinjection nozzle across the width of the housing are located a distancealong the central axis from an end of the housing closest thereto thatis about equal to the width of the housing divided by two times thenumber of injection nozzles.
 14. A rotary feeder comprising: astationary, cylindrical housing having disposed therein a number ofinjection nozzles, and within which rotate a plurality of vanes about acentral axis, wherein the housing extends a width along the centralaxis, wherein each of the vanes has a length along the central axis,wherein the injection nozzles are positioned across the width of thehousing, such that a spray pattern of a gas injected via the number ofinjection nozzles spans substantially the entire length of the vanes,wherein each of the number of injection nozzles is located at a positionalong a circumference of the housing that is in the range of from about50° to about 170° from an inlet of the rotary feeder, along a directionof rotation of the plurality of vanes, and wherein each of the number ofinjection nozzles is fluidly connected with a gas source via a gas feedline.
 15. The rotary feeder of claim 14, wherein each of the number ofinjection nozzles is located at a position along a circumference of thehousing that is in the range of from about 90° to about 160° from theinlet, along the direction of rotation of the plurality of vanes. 16.The rotary feeder of claim 14, wherein the stationary, cylindricalhousing defines the inlet and an outlet, wherein the inlet is positionedat a top of the housing, and the outlet is positioned at a bottom of thehousing.
 17. The rotary feeder 14, wherein the length of each of theplurality of vanes is slightly less than the width of the housing alongthe central axis, such that the each of the plurality of vanes extendsalmost to the end walls of the housing and can rotate freely within thehousing.
 18. The rotary feeder of claim 14, wherein pairs of adjacentvanes of the plurality of vanes define wedge volumes.
 19. A rotaryfeeder comprising: a stationary, cylindrical housing having disposedtherein a number of injection nozzles, and within which rotate aplurality of vanes about a central axis, wherein the housing extends awidth along the central axis from end walls thereof, wherein each of thevanes extends a length along the central axis, wherein the length eachof the plurality of vanes extends along the central axis is slightlyless than the width of the housing along the central axis, such that theeach of the plurality of vanes extends almost to the end walls of thehousing and can rotate freely within the housing, wherein the injectionnozzles are positioned across the width of the housing, such that aspray pattern of a gas injected via the number of injection nozzlesspans substantially the entire length of the vanes, and wherein each ofthe number of injection nozzles is fluidly connected with a gas sourcevia a gas feed line.
 20. The rotary feeder of claim 19, wherein thelength of each of the plurality of vanes is less than 1.0 inch (25.4 mm)less than the width of the housing.